Laminate Facing for Fiber Reinforced Materials and Composite Materials Formed Therefrom

ABSTRACT

The present invention provides a laminate material having a polyester film and a web of polyester fibers cohesively bonded directly thereto, such that portions of the fibers are bonded to the polyester film and portions of the fibers are free from the polyester film. The invention may also include a glass reinforced polymer layer formed on the laminated facer where the polymer of the glass reinforced polymer layer is commingled with the nonwoven of the laminated facer. The laminate may further include a second polymer layer having a thickness joined to the fiber layer and/or a layer of hot melt adhesive applied to the polyester fibers. Also presented is a composite material having a polyester film, a layer of polyester fibers bonded to the second polymer layer; a second polymer layer joined to the polyester film; and a glass reinforced polymer layer formed on the laminated facer, where the polymer of the glass reinforced polymer layer is commingled with the nonwoven of the laminated facer.

PRIORITY

This Application is a Continuation-In-Part of U.S. application Ser. No. 13/851,662, filed Mar. 27, 2013, which is a Utility Application based upon Provisional Application Ser. No. 61/616,863, filed Mar. 28, 2012, entitled, “Laminate Facing for Fiber Reinforced Materials and Composite Materials Formed Therefrom” with Inventor: Thomas Miller. All aspects of Provisional Application Ser. No. 61/616,863 are hereby incorporated by reference.

BACKGROUND

Polypropylene films are often used as surface materials for laminates and composite materials, are known for use in lining trucks, refrigerated shipping containers and other industrial and construction materials. Typically, a film such as polypropylene or other substrate such as PET is bonded to a nonwoven. The polypropylene face layer is not a suitably durable, temperature resistant or chemically inert surface. The polypropylene facers are generally not suitable for use with a thermoset composite due to adherence issues and temperature resistance. Polypropylene is typically porous and difficult to clean and is therefore generally not suitable for use for a number of applications. The polypropylene laminate is formed with a film of polypropylene, to which a layer of polypropylene is extruded and the extruded polypropylene adheres to the film and the nonwoven material. The three-step process increases material costs, processing expense and material waste.

SUMMARY

In accordance with embodiments, the present invention relates to laminate facings for fiber reinforced or composite materials and materials formed therefrom. The laminate facings are generally formed of a polyester film layer bonded directly to a nonwoven fibrous layer. The facings are cohesively bonded to a nonwoven, typically roll bonded, point bonded or bonded by any other suitable method, including coforming of the fiber layer on the film or the film layer on the fibrous layer directly such that the fibers and the polyester film facing are integrally joined without the use of a subsequently applied layer of adhesive or other polymer. The composite materials may be formed by applying the laminate to a surface and depositing fiber reinforced resin to the laminate or applying the laminate to the surface of a fiber-reinforced resin during manufacture. The laminate provides a rugged outer layer for composite materials and may reduce volatile organic compound emissions by replacing a gel coat layer. The laminate may also include a metalized layer such as aluminum, molybdenum, tantalum, titanium, nickel, and tungsten. The metalized layer improves thermal properties by forming a radiant barrier and also improves opacity of the facing and provides an aesthetically pleasing appearance.

In accordance with embodiments of the present invention the films may be produced by conventional forming such as casting, blowing, and extrusion or coextrusion processes. The extruded films are created with a single base layer made from an extrudable thermoplastic polymer and may include one or more exterior layers. One suitable exterior layer includes a relatively low melting point heat sealable polymer to improve the bonding of the film to the fibrous layer. The bonding material of the film is a heat sealable polymer layer designed to melt bond to the polymer of the fiber layer. In an alternate embodiment of the present invention, a metalized or ink layer may be deposited on one surface or both surfaces of the laminate.

Bicomponent fibers may be incorporated into nonwovens by several processes. The spunbond process may be adapted to create bicomponent fibers of a sheath/core type, and lay these fibers continuously onto a conveyor wherein they can be consolidated into a nonwoven web and wound into a roll. Consolidation may be provided by heated rolls either of a pattern including point bonding, or more preferably in this case of smooth surfaces to provide more uniform bonding over the entire surface of the nonwoven web of continuous fibers.

Alternatively, Bicomponent fibers may be produced and then cut and crimped into staple fibers. Staple fibers may then be blended and mixed with other fiber types and dimensions, then carded and run onto a conveyor wherein they can be consolidated into a nonwoven web and wound into a roll. Consolidation may be provided by heated rolls either of a pattern including point bonding, or more preferably in this case of smooth surfaces to provide more uniform bonding over the entire surface of the nonwoven web of continuous fibers.

There are several advantages for using staples fiber blends for processing, performance, and cost. A notable difference between the two described methods is that a nonwoven web formed of continuous fibers is formed of layers of superimposed fibers, whereas a nonwoven web of staple fibers has substantial interleaving of the fibers such that each fiber may be present in part on both top and bottom surfaces. While a spunbond line adapted for the production of bicomponent fibers may only provide a singular specification of fiber for a given layer of the nonwoven, a production line using staple fibers may blend several types of fibers throughout the nonwoven web. Staple fiber blending is common and easily controlled, and the benefits of blending can provide enhancements of performance and cost. In addition, a production line using staple fibers may be more easily controlled for speed to provide greater flexibility of the weight of nonwoven achieved as well as the introduction of films into the process.

In accordance with an alternate embodiment of the present invention is presented having a composite material of a laminated facer having a polyester film with a thickness of 0.5-5 mil and a layer of polyester fibers having a density of 17-100 GSM bonded thereto; and a glass reinforced polymer layer formed on the laminated facer where the polymer of the glass reinforced polymer layer is commingled with the nonwoven of the laminated facer.

In accordance with an alternate embodiment of the present invention is presented having a laminate material having a polyester film having a thickness of 0.5-2 mil, a layer of polyester fibers having a density of 17-70 GSM bonded to the polyester film and a second polymer layer having a thickness of 0.5-5.5 mil joined to the polyester fibers.

In accordance with an alternate embodiment of the present invention is presented having a composite material having a polyester film having a thickness of 0.5-2 mil, a layer of polyester fibers having a density of 17-70 GSM bonded to the film, a second polymer layer having a thickness of 0.5-5.5 mil joined to the polyester fibers and a glass reinforced polymer layer formed on the laminated facer.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete appreciation of the invention and the many embodiments thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:

FIG. 1A illustrates a plan view of the formation of the laminate material in accordance with one aspect of the present invention;

FIG. 1B illustrates a plan view of the formation of the laminate material in accordance with another aspect of the present invention;

FIG. 2A illustrates a plan view of the printing of the laminate material in accordance with one aspect of the present invention.

FIG. 2B illustrates a plan view of the metallization of the laminate material in accordance with one aspect of the present invention.

FIG. 3 illustrates a plan view of the composite material of the present invention with a laminate layer and a non-woven included.

FIG. 4A is a schematic top view of the laminate of the present invention

FIG. 4B is a schematic cross sectional view of the laminate of the present invention.

FIG. 5 is a schematic cross sectional view of another laminate of the present invention including an adhesive layer or filler layer applied to the nonwoven layer.

FIG. 6A is a cross-sectional schematic view of a preform (prior to consolidation) of a laminate in accordance with one aspect of the present invention with a single fiber of a monocomponent fiber web on a laminated polymer film.

FIG. 6B is a cross-sectional schematic view of a laminate in accordance with one aspect of the present invention with a single fiber of a monocomponent fiber web consolidated with a laminated polymer film.

FIG. 6C is a cross-sectional schematic view of a laminate in accordance with one aspect of the present invention with a single fiber of a monocomponent fiber web consolidated with a laminated polymer film with a film applied to the fiber side of the laminate.

FIG. 6D is a cross-sectional schematic view of a preform (prior to consolidation) of a laminate in accordance with one aspect of the present invention with a single fiber of a bicomponent fiber web on a laminated polymer film.

FIG. 6E is a cross-sectional schematic view of a laminate in accordance with one aspect of the present invention with a single fiber of a bicomponent fiber web consolidated with a laminated polymer film such that the polymer of the polymer layer and the polymer of the bicomponent fiber are merged.

FIG. 6F is a cross-sectional schematic view of a laminate in accordance with one aspect of the present invention with a single fiber of a bicomponent fiber web consolidated with a laminated polymer film with a film applied to the fiber side of the laminate.

FIG. 7A is a cross-sectional schematic view of a laminate in accordance with one aspect of the present invention with a fiber web of mixed monocomponent and bicomponent fiber web consolidated with a laminated polymer.

FIG. 7B is a cross-sectional schematic view of a laminate in accordance with one aspect of the present invention with a fiber web of mixed monocomponent and bicomponent fiber web consolidated with a laminated polymer film with a film applied to the fiber side of the laminate.

FIG. 7C is a cross-sectional schematic view of a laminate in accordance with one aspect of the present invention with a fiber of a mixed monocomponent and bicomponent fiber web consolidated with a laminated polymer film and having a subsequent polymer layer deposited over the fiber web.

FIG. 8A is a cross-sectional schematic view of a laminate in accordance with one aspect of the present invention with a fiber of a mixed monocomponent and bicomponent fiber web consolidated with a laminated polymer film and having a subsequent polymer layer deposited over the fiber web and an additional layer deposited on the laminated polymer film.

FIG. 8B is a cross-sectional schematic view of a laminate in accordance with one aspect of the present invention with a fiber of a mixed monocomponent and bicomponent fiber web consolidated with a laminated polymer film and having a subsequent polymer layer deposited over the fiber web and an additional layer deposited on the laminated polymer film and a building material layer, such as stucco applied over the laminate.

FIG. 8C is a cross-sectional schematic view of a laminate in accordance with one aspect of the present invention with a fiber of a mixed monocomponent and bicomponent fiber web consolidated with a laminated polymer film and having a number of subsequent polymer layers deposited over the fiber web.

DETAILED DESCRIPTION

The present invention will now be described with occasional reference to the specific embodiments of the invention. This invention may, however, be embodied in different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art.

Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The terminology used in the description of the invention herein is for describing particular embodiments only and is not intended to be limiting of the invention. As used in the description of the invention and the appended claims, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise.

Unless otherwise indicated, all numbers expressing quantities of ingredients, properties such as molecular weight, reaction conditions, and so forth as used in the specification and claims are to be understood as being modified in all instances by the term “about”. Accordingly, unless otherwise indicated, the numerical properties set forth in the specification and claims are approximations that may vary depending on the desired properties sought to be obtained in embodiments of the present invention. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical values, however, inherently contain certain errors necessarily resulting from error found in their respective measurements.

Fibrous nonwoven webs provide an improved bonding surface between a polymer film layer and a fiber reinforced polymer composite material. Preferred nonwoven webs are formed with staple fibers that are carded and then may be bonded with a heat and/or pressure process such as hot calendering, including area bonding, point bonding and embossing; belt calendering; through-air thermal bonding; ultrasonic bonding; or radiant-heat bonding. The web may be additionally, or alternatively, chemically bonded to improve mechanical properties. Many bonding methods are available including powder bonding using a powdered adhesive added to the web and then typically heated. In a preferred embodiment, point or pattern bonding using heated calender rolls or ultrasonic bonding equipment is used to bond the fibers together. Point bonding provides for a secure bonding of the nonwoven to the polyester film while leaving unbonded fibers available to commingle with the composite laminate or other coating resin. Roll bonding may be used to bond the web across its entire surface. Bicomponent or multicomponent staple fibers may be used in the process as well and generally, a blend of single component fibers and bicomponent fibers is preferred.

As seen in FIG. 1A, roll 16 of polymer film 18 and roll 12 of nonwoven 14 is laminated by calender rolls 20, 22. The resulting laminate 24 is taken up roll 26. The polymer film is preferably 0.5-5.0 mil thick. A polyester film such as polyethylene terephthalate sold under the trade names Mylar, Skyrol, Melinex or Hostaphan may be used. Generally, the bonding temperature is 130-180° C. Preferably, a temperature of about 140-170° C. is to be used in the bonding process. The fibers and the polyester film facing are cohesively bound, that is, integrally joined without the use of an intermediate layer of adhesive or other polymer. As shown in TABLE 1, a layer of polypropylene or another polymer or a lower grade of polyester may be applied to the nonwoven. The use of lower cost polymers may substantially decrease the overall cost of the material without substantially altering the properties.

In FIG. 1B, the polymer film 18 in taken off roll and fed into nonwoven fiber deposition device 10 such that nonwoven 12 is applied to film 18 and the nonwoven 12 and film 18 are laminated by calender rolls 20, 22. The resulting laminate 24 is taken up roll 26. FIG. 2A shows the printing process in which laminate 24 is unrolled from roll 26 fed through a printing device to form a printed laminate 30 that is rolled onto take-up roll 32.

FIG. 2B shows the vapor deposition of metallic compounds in which laminate 24 is unrolled from roll 26 fed through a deposition device to form a metalized laminate 30, which is rolled onto take-up roll 32. Various deposition methods may be used including chemical vapor deposition, physical vapor deposition. Metals such as molybdenum, tantalum, titanium, nickel, and tungsten are generally applied by CVD. For the deposition of aluminum, CVD may be used with tri-isobutyl aluminum, tri ethyl/methyl aluminum, or dimethyl aluminum hydride precursors or a physical deposition process may be used. Electrostatic spray assisted vapor deposition, plasma and electron-beam deposition may also be used. The metalized layer may be formed on either the polyester film layer or the non-woven layer. It may also be advantageous to deposit a metallic coating on both sides of the laminate for improved coverage, durability, and aesthetics.

FIG. 3 shows a composite material 38 including a resin layer 36 including fibers 40 and laminate 24. Laminate 24 includes polymer film layer 18 bonded to nonwoven 14. The resin 36 infuses into the fibers of the nonwoven layer to provide an integrated mechanical bond. The mechanical bond formed between the resin 36 and the fibers of nonwoven layer 14 is substantially stronger than the chemical bond formed between the resin and the surface of the polymer layer 18. Any resin infusion technology, such as liquid molding, resin transfer molding, vacuum assisted resin transfer molding, vacuum infusion processing and composite infusion molding processing as well as vacuum bag molding, open molding, press molding, may be used to form composite member 38. Other processes such as hot calendering of the laminate onto the resin layer or use of the laminate as a surface film in pulltrusion may be used to form composite member 38.

FIG. 4A and FIG. 4B show the point bonded laminate of the present invention including a non-woven layer 14 positioned on poly film 18. The point bonding sites 14′ are formed by rollers 20, 22 (as shown in FIG. 1). The point bond sites 14′ are substantially compressed such that the polymer of the fibers in the nonwoven 14 is integrally joined with the polymer of the film 18. One or both of the rollers 20, 22 may be heated to melt the fibers to bond with film 14.

FIG. 5 shows another embodiment of the laminate 44 including a polymer film 18, a fibrous layer 24 and a polymer layer 46 applied to the nonwoven layer with bonding sites 14′ bonding film 18 to fibers 24. The laminate may be formed as described above to form a laminate material having a polyester film having a thickness of 0.5-2 mil; a layer of polyester fibers having a density of 17-70 GSM bonded polyester film and a polymer layer of polyethylene, polyvinylidene fluoride, poly(methyl methacrylate), polycarbonate, acrylonitrile butadiene styrene, polyvinyl fluoride, polyester, polyurethane, polypropylene, polyethylene terephthalate, polyurea, polyvinyl chloride, EMA, or EVA. A second polymer 46 may also be a hot melt adhesive applied to the fibers. The hotmelt adhesives may be any known including Ethylene-vinyl acetate (EVA) copolymers, Ethylene-acrylate copolymers such as ethylene n-butyl acrylate (EnBA), ethylene-acrylic acid (EAA) and ethylene-ethyl acetate (EEA), Polyolefins such as low or high density polyethylene, atactic polypropylene, polybutene-1, and oxidized polyethylene, Polybutene-1 and its copolymers, Amorphous polyolefin polymers, Polyamides and polyesters, Polyurethanes, Thermoplastic polyurethane, reactive urethanes, Styrene block copolymers such as Styrene-butadiene-styrene such as Styrene-isoprene-styrene, Styrene-ethylene/butylene-styrene, and Styrene-ethylene/propylene. Other hotmelt adhesives may include Polycaprolactone Polycarbonates, Fluoropolymers, Silicone rubbers, Thermoplastic elastomers and Polypyrrole may also be used.

FIG. 6A is a cross-sectional schematic view of a preform of a laminate formed with a film having base layer 110 and heat sealable layer 112 with a single monocomponent fiber 114 of a monocomponent fiber web. At the junction of fiber 114 and layer 112 recesses 114′, 114″ are formed.

FIG. 6B is a cross-sectional schematic view of a laminate formed with layers, 110, 112 with a single monocomponent fiber 114 of a monocomponent fiber web consolidated thereto. Heat sealable polymer layer 112 is formed of a lower melting point material than fiber that when the fiber 114 and layer 112 are consolidated by heat and pressure, heat sealable layer 112 Recesses 114′, 114″ formed at the junction of fiber 114 and layer 112, remain after consolidation of the fiber 114 and layer 112.

FIG. 6C is a cross-sectional schematic view of a laminate formed with layers, 110, 112 with a single monocomponent fiber 114 of a monocomponent fiber web consolidated thereto. Preferably, polymer layer 112 and fiber 114 are formed of a compatible or miscible material such that when the fiber 114 and layer 112 are consolidated by heat and pressure there is no substantial variation in the material. An additional layer 122 is shown over layer 112 and fiber 114, Layer 122 maybe any suitable material, such as an additional polymer layer or a metallization layer a printing ink, or successive combination thereof. Junctions of fiber 114 and layer 112 form along the length of fiber 114 such that fiber 114 is anchored in areas and free from layer 112 in areas. The unanchored areas of fiber 114 may be completely surrounded by subsequent polymer layers to form a strong mechanical bond.

FIG. 6D is a cross-sectional schematic view of a preform of a laminate formed with layers, 110, 112 with a single multicomponent fiber 116 of a fiber web. Multicomponent fiber 116 may include core 118 and clad layer 120 or may be and other suitable multicomponent fiber structure. At the junction of fiber 116 and layer 112 recesses 116′, 116″ are formed. As with fiber 114, junctions of fiber 116 and layer 112 form along the length of fiber 116 such that fiber 116 is anchored in areas and free from layer 112 in areas. The unanchored areas of fiber 116 may be completely surrounded by subsequent polymer layers to form a strong mechanical bond.

FIG. 6E is a cross-sectional schematic view of a laminate formed with a film having layers, 110, 112 with a single multicomponent fiber 116 of a fiber web consolidated thereto. Preferably, polymer layer 112 and sheath layer 120 are formed of a compatible or miscible material such that when the fiber sheath 120 and layer 112 are consolidated by heat and pressure there is no substantial variation in the material. Typically, with a core clad fiber the clad layer 120 would be compatible with layer 112. Recesses 116′, 116″ formed at the junction of fiber 116 and layer 112, remain after consolidation of the fiber 116 and layer 112.

FIG. 6F is a cross-sectional schematic view of a laminate formed with layers, 110, 112 with a single multicomponent fiber 114 of a fiber web consolidated thereto. An additional layer 122 is shown over layer 112 and fiber 114, Layer 122 maybe any suitable material, such as an additional polymer layer, a metallization layer, printing ink, or a combination thereof. Recesses 116′, 116″ formed at the junction of fiber 116 and layer 112, remain after consolidation of the fiber 116 and layer 112 and the subsequent deposition of layer 122.

FIG. 7A is a cross-sectional schematic view of a preform of a laminate formed with film layers, 110, 112 with monocomponent fibers 114, 130 and multicomponent fiber 116, shown with core 118 and clad layer 120 or may be another suitable multicomponent fiber structure. At the junction of fiber 114 and layer 112 recesses 114′, 114″ are formed and at the junction of fiber 116 and layer 112 recesses 116′, 116″ are formed. Fibers 130 and 114 are generally the same blended and carded fibers diameter as fed into the web processing steps.

FIG. 7B is a cross-sectional schematic view of a laminate formed with layers, 110, 112 with a single monocomponent fiber 114 and a single multicomponent fiber 120 of a mixed fiber web consolidated thereto. Preferably, polymer layer 112, fiber 114 and a portion of fiber 116 are formed of a compatible or miscible material such that when the fibers 114, 116 and layer 112 are consolidated by heat and pressure there is no substantial variation in the material. Typically, with a core clad fiber the clad layer 120 would be compatible with layer 112. Recesses 114′, 114″ formed at the junction of fiber 114 and layer 112 and recesses 116′, 116″ formed at the junction of fiber 116 and layer 112, and remain after consolidation of the fiber 114 and layer 112. An additional layer 122 is shown over layer 112 and fiber 114, Layer 122 maybe any suitable material, such as an additional polymer layer or a metallization layer.

FIG. 7C is a cross-sectional schematic view of a preform of a laminate formed with layers, 110, 112 with monocomponent fiber 114, and multicomponent fibers 116, 132, shown with core 118 and clad layer 120 and core 136 and clad layer 134 or may be and other suitable multicomponent fiber structure. At the junction of fiber 114 and layer 112 recesses 114′, 114″ are formed and at the junction of fiber 116 and layer 112 recesses 116′, 116″ are formed. Additional polymer layer 138 is applied to fibers 114, 116, 132 such that a chemical bond is formed therebetween and a mechanical bond is formed when polymer layer 138 surrounds a portion of the fiber at recesses 114′ and 116′ as well as the circumference of fibers 114, 116 where the fibers are not joined to layer 112 or to fiber 132.

FIG. 8A is a cross-sectional schematic view of a composite material including a laminate formed with layers, 110, 112, 158 with a single monocomponent fiber 114 and a single multicomponent fiber 120 of a mixed fiber web consolidated thereto. Alternatively, layer 158 may be applied in a post-processing step to include. Preferably, polymer layer 112 and a clad layer 118 of fiber 116 are formed of a compatible or miscible material such that when the fibers 116 and layer 112 are consolidated by heat and pressure there is no substantial variation in the material. Typically, with a core clad fiber the clad layer 120 would be compatible with layer 112. Recesses 114′, 114″ formed at the junction of fiber 114 and layer 112 and recesses 116′, 116″ formed at the junction of fiber 116 and layer 112, and remain after consolidation of the fiber 114 and layer 112. An additional layer 122 is shown over layer 112 and fiber 114, Layer 122 maybe any suitable material, such as an additional polymer layer or a metallization layer. Additional layer 138 such as a fiber reinforced composite material is applied to fibers 114, 116, 132 such that a mechanical bond is formed with the recesses 114′ and 116′and around the circumference of unbonded regions of fiber 114, 116.

FIG. 8B is a cross-sectional schematic view of a laminate formed with layers, 110, 112 and additional layer 160 with a single monocomponent fiber 114 and a single multicomponent fiber 120 of a mixed fiber web consolidated thereto. Preferably, polymer layer 112, fiber 114 and a portion of fiber 116 are formed of a compatible or miscible material such that when the fibers 114, 116 and layer 112 are consolidated by heat and pressure there is no substantial variation in the material. Typically, with a core clad fiber the clad layer 120 would be compatible with layer 112. Recesses 114′, 114″ formed at the junction of fiber 114 and layer 112 and recesses 116′, 116″ formed at the junction of fiber 116 and layer 112, and remain after consolidation of the fiber 114 and layer 112. An additional layer 122 is shown over layer 112 and fiber 114, Layer 122 maybe any suitable material, such as an additional polymer layer or a metallization layer. Additional polymer layer 138, such as a fiber reinforced polymer, is applied to fibers 114, 116, 132 such that a chemical bond is formed therebetween and a mechanical bond is formed with the recesses 114′ and 116′ as well as the circumference of fibers 114, 116 where the fibers are not joined to layer 112. Exterior layer 160 such as a building material, for example, a foamed polymer, and adhesive layer or a cementitious stucco may be applied after the laminate is mounted to a wall.

FIG. 8C is a cross-sectional schematic view of a preform of a laminate formed with layers, 110, 112 with monocomponent fiber 114, and multicomponent fibers 116, 132, shown with core 118 and clad layer 120 and core 136 and clad layer 134 or may be and other suitable multicomponent fiber structure. Additional layers fiber of reinforced composite material may be applied such that the polymer matrix of the composite saturates the fiber layer of the Film/Fiber Laminate 150, 152, 154, 156 may be added to form a composite such as a four-ply structure with fiber alignment of 0/90/90/0.

The laminate and composite material of the present invention is suitable for use in any composite structures including truck and trailer liners, refrigerated shipping container liners, ladder rails, tool handles, window lineals, structural materials, wall panels for use in food preparation, health care or sanitary applications, wall panels for recreational vehicles, polls and cross arms, pilings or other infrastructure applications, and signage; or electronic materials such as substrates for electronic boards, laminates for solar panels, integrated circuits, industrial switching, capacitors, and electrical boards; and insulation such as foam facers, glass or mineral wool facers, and radiant heat barriers.

EXAMPLES

Generally, polyester layers are combined with nonwoven layers a wide range of potential laminates is shown in TABLE 1. The polyester film used in each trial ranged from 48 to 200 gauge thickness. The spunbond nonwoven ranges from 34-50 GSM. The PP/Glass composite fiber is 50% glass fibers and 50% polypropylene fibers.

The examples cited in Table 1. Include spunbond continuous monocomponent fibers, (examples 1A, 1B, 2), spunbond continuous bicomponent fibers, (examples 3, 4), and staple (discontinuous) bicomponent fibers blended with monocomponent fibers (examples 5, 6, 7, 8).

Examples 1A and 1B were produced at the same time, and example 1B had the additional process of application of a coating of Polypropylene applied to the fiber side. They were each then laminated to a similar composite of Fiberglass and Polypropylene. The tests demonstrated an improvement is shear performance with the coating of example 1B.

Example 2 was produced analogous to examples 1 and then additional processed by ultrasonic bonding. Subsequent tests confirmed an increase of peel strength.

Examples 3 and 4 demonstrated improved peel strength when using the continuous bicomponent fibers.

Examples 5, 6, 7, 8 demonstrated further improved peel strength when using the staple (discontinuous) bicomponent fibers blended with monocomponent fibers, and substantially higher shear strength. This was confirmed for a range of film thickness and fiber weights.

In Examples, 3-8 bicomponent fibers having a 50/50 ratio of core to sheath are used. Any suitable multicomponent fiber may be used provided that a relatively low melting point polymer is available at the surface of the fiber for bonding.

The polypropylene layer of example 1B is applied at 108 GSM (˜3.5 mils thick). The use of a second polymer layer improves the strength of the final bond to the composite board, improving the shear strength from 175 PSI to 235 PSI. The use of sheath/core fibers substantially increased the peel and shear strengths.

TABLE 1 

What is claimed is:
 1. A laminate material comprising: a base layer of a polymer film a heat sealable polymer film having a thickness of 0.5-5 mil, and a bonded fiber web having a density of 17-100 GSM and including polymer fibers cohesively bonded directly thereto, such that portions of the fibers are bonded to the polymer film and portions of the fibers are free from the polymer film.
 2. The laminate material of claim 1, wherein the polymer film is a polyester film.
 3. The laminate material of claim 1, wherein the polymer film is a polyethylene terephthalate film.
 4. The laminate material of claim 1, wherein the polymer fibers comprise polyester.
 5. The laminate material of claim 1, wherein the polymer polyethylene terephthalate.
 6. The laminate material of claim 1, wherein the polymer film is selected from the group consisting of polyethylene, polyvinylidene fluoride, poly(methyl methacrylate), polycarbonate, acrylonitrile butadiene styrene, polyvinyl fluoride, polyester, polyurethane, polypropylene, polyethylene terephthalate, polyurea, polyvinyl chloride, EMA, or EVA.
 7. The laminate material of claim 1, wherein the polymer fibers are selected from the group consisting of polyethylene, polyvinylidene fluoride, poly(methyl methacrylate), polycarbonate, acrylonitrile butadiene styrene, polyvinyl fluoride, polyester, polyurethane, polypropylene, polyethylene terephthalate, polyurea, polyvinyl chloride, EMA, or EVA.
 8. The laminate material of claim 1, wherein the base layer has a softening point T1 and the and the heat sealable layer has a softening point T2, such that T2<T1.
 9. The laminate material of claim 1, wherein the monocomponent fibers have a softening point T3 such that T3>T2.
 10. The laminate material of claim 1, wherein a polymer in the multicomponent fibers has a softening point T4 such that T4<T1
 11. The laminate of claim 1, wherein the bonded fiber web includes a mixture of monocomponent fibers and multicomponent fibers.
 12. The laminate of claim 1, wherein the bonded fiber has a density of 20-50 GSM and the web includes staple fibers.
 13. The laminate of claim 1, wherein the bonded fiber has a density of 20-50 GSM and the web includes continuous fibers.
 14. The laminate of claim 1, wherein the cohesive bond is selected from the group consisting of melt bonding, point bonding and roll bonding.
 15. The laminate of claim 1, further comprising: a layer selected from the group consisting of: a metal layer, an ink layer, a polymer layer deposited on at least one surface of the laminate.
 16. The laminate of claim 1, further comprising: a layer applied to the base layer opposite heat sealable layer, the layer se

polymers (polyethylene, low melt PET, acrylic, polyurethane, ink, polyester, polypropylene, polyethylene terephthalate, polyurea or polyvinyl chloride) or a vapor deposited metals
 17. The laminate of claim 1, wherein the polyester film has a thickness of 0.5-3.0 MIL.
 18. The laminate of claim 1, wherein the polyester film has a thickness of 0.5-3.0 MIL and the nonwoven has a density of 30-65 GSM.
 18. The laminate of claim 1, wherein the polyester film has a thickness of 0.5-1.5 MIL and the nonwoven has a density of 17-35 GSM.
 19. The laminate of claim 1, further comprising: an extrusion coated polymer layer having a thickness of 30-260 GSM joined to the nonwoven.
 20. The laminate of claim 19, wherein the extrusion coated polymer layer is selected from the group consisting of polyethylene, polyester, polyurethane, polypropylene, polyethylene terephthalate, polyurea, polyvinyl chloride, EMA, or EVA.
 21. A composite material, comprising: a laminated facer having a polymer film having a thickness of 0.5-5 mil and a bonded fiber web having a density of 17-100 GSM fibers being cohesively bonded directly to the polymer film, such that portions of the fibers are bonded to the polymer film and portions of the fibers are free from the polymer film; and a fiber reinforced polymer layer formed on the laminated facer; whereby, the polymer of the reinforced polymer layer is commingled with the nonwoven of the laminated facer.
 22. The composite material of claim 21, wherein the polymer film is a polyester film.
 23. The composite material of claim 21, wherein the polymer film is a polyethylene terephthalate film.
 24. The composite material of claim 21, wherein the polymer fibers comprise polyester.
 25. The composite material of claim 21, wherein the polymer polyethylene terephthalate.
 26. The composite material of claim 21, wherein the polymer film is selected from the group consisting of polyethylene, polyvinylidene fluoride, poly(methyl methacrylate), polycarbonate, acrylonitrile butadiene styrene, polyvinyl fluoride, polyester, polyurethane, polypropylene, polyethylene terephthalate, polyurea, polyvinyl chloride, EMA, or EVA.
 27. The composite material of claim 21, wherein the polymer fibers are selected from the group consisting of polyethylene, polyvinylidene fluoride, poly(methyl methacrylate), polycarbonate, acrylonitrile butadiene styrene, polyvinyl fluoride, polyester, polyurethane, polypropylene, polyethylene terephthalate, polyurea, polyvinyl chloride, EMA, or EVA.
 28. The material of claim 21, further comprising: a layer selected from the group consisting of: a metal layer, an ink layer, a polymer layer deposited on at least one surface of the laminate.
 29. The laminate of claim 21, wherein the polyester film has a thickness of 0.5-3.0 MIL and the nonwoven has a density of 17-50 GSM.
 30. A laminate material comprising: a polyester film having a thickness of 0.5-2 mil, a bonded fiber web having a density of 17-100 GSM and including 20% PET fibers and 80% PET bicomponent fibers cohesively bonded directly to the polyester film, such that portions of the fibers are bonded to the polyester film and portions of the fibers are free from the polyester film. 